Gledhill BoilerMate 2000 Owner's manual

Brand: Gledhill

Model: BoilerMate 2000

Category: Water heaters & boilers

Type: Owner's manual

DESIGN, INSTALLATION AND

SERVICING INSTRUCTIONS

AN OPEN VENTED CENTRAL HEATING

AND MAINS PRESSURE HOT WATER SUPPLY

SYSTEM INCORPORATING

A THERMAL STORE

ALL MODELS COMPLY WITH THE

WATER HEATER MANUFACTURERS

SPECIFICATION FOR INTEGRATED THERMAL

STORES

BOILERMATE

2000

BOILERMATE

2000

benchmark

The code of practice for the installation,

commissioning & servicing of central heating systems

Gas Council Approved Reference Numbers

BoilerMate 125 89-317-04A

BoilerMate 145 89-317-05A

BoilerMate 185 89-317-06A

BoilerMate 210 89-317-07A

BoilerMate 225 89-317-08A

Page 2

CONTENTS

Section Page

1.0 DESIGN

1.1 Introduction 3

1.2 Technical Data 5

1.3 System Details 10

2.0 INSTALLATION

2.1 Site Requirements 18

2.2 Installation 19

2.3 Commissioning 27

3.0 SERVICING

3.1 Annual Servicing 31

3.2 Changing Components 31

3.3 Short Parts List 32

3.4 Fault Finding 34

Appendix A 36

Appendix B 37

Appendix C 40

Appendix D 41

Appendix E 42

Terms & Conditions

The Gledhill BoilerMate range is a WBS

listed product and complies with the WMA

Speciﬁ cation for integrated thermal storage

products. The principle was developed in

conjunction with British Gas. This product

is manufactured under an ISO 9001:2000

Quality System audited by BSI.

Patents Pending

The Gledhill Group’s ﬁ rst priority is to give a

high quality service to our customers.

Quality is built into every Gledhill product

and we hope you get satisfactory service

from Gledhill.

If not please let us know.

ISSUE 10: 06-08

As part of the industry wide “Benchmark” Initiative all Gledhill BoilerMates now

include a Benchmark Installation, Commissioning and Service Record Log Book.

Please read carefully and complete all sections relevant to the appliance installation.

The details of the Log Book will be required in the event of any warranty work being

required. There is also a section to be completed after each regular service visit.

The completed Log Book and these instructions should be left in the pocket

provided on the back of the front panel.

benchmark

The code of practice for the installation,

commissioning & servicing of central heating systems

Page 3

BOILERMATE

2000

1.0 DESIGN

1.1 INTRODUCTION

These instructions should be read in

conjunction with the Installation and Servicing

Instructions issued by the manufacturers of

the heat source e.g. the boiler used.

Any water distribution and central heating

installation must comply with the relevant

recommendations of the current version of

the Regulations and British Standards listed

below:-

Gas Safety Regulations

Building Regulations

I.E.E. Requirements for Electrical Installations

Water Regulations

British Standards

BS6798, BS5449, BS5546, BS5440:1, BS5440:2,

CP331:3, BS6700, BS5258, BS7593 and BS7671.

A competent person as stated in the Gas

Safety Regulations must install the BoilerMate

heating system. The manufacturer’s notes

must not be taken as overriding statutory

obligations.

The BoilerMate 2000 is only suitable for use

with an open vented central heating system.

The BoilerMate 2000 is not covered by section

G3 of the current Building Regulations and is

therefore not notiﬁ able to Building Control.

The information in this manual is provided to

assist generally in the selection of equipment.

The responsibility for the selection and

speciﬁ cation of the equipment must however

remain that of the customer and any Designers

or Consultants concerned with the design and

installation.

Please Note: We do not therefore accept any

responsibility for matters of design, selection

or speciﬁ cation or for the effectiveness of an

installation containing one of our products

unless we have been speciﬁ cally requested

to do so.

All goods are sold subject to our Conditions

of Sale, which are set out at the rear of this

manual.

In the interest of continuously improving

the BoilerMate range, Gledhill Water Storage

Ltd reserve the right to modify the product

without notice, and in these circumstances

this document, which is accurate at the time

of printing, should be disregarded. It will

however be updated as soon as possible after

the change has occurred.

Page 4

The BoilerMate 2000 shown schematically above is designed to provide improved space

heating and mains pressure hot water when coupled to any remotely sited condensing

or non condensing boiler - as long as they comply with the recommendations

contained in the rest of this manual.

A report by the Cranﬁ eld Institute of Technology found that this system gives a

potential for energy savings of up to 15%.

Because of the efﬁ ciency of the appliance improved SAP ratings can be achieved.

Further details are available from the Gledhill Technical Department.

The principle of a BoilerMate 2000 is to separate the heat generator e.g. a boiler

from heat emitters (radiators) by a thermal store, which evens out the ﬂ uctuating

demands for heating and hot water. Thus, by storing energy produced when the

demand is low and discharging it when the demand is high (i.e. during property

warm up or when hot water is drawn off), a smaller boiler can potentially be used.

An important feature of this concept is that hot water can be supplied directly from

the mains at conventional ﬂ ow rates without the need for temperature and pressure

relief safety valves or expansion vessels. This is achieved by passing the mains

water through a plate heat exchanger. The outlet temperature of the domestic

hot water is maintained by a printed circuit board, which controls the speed of

the pump circulating the primary water from the store through the plate heat

exchanger.

To comply with the Benchmark Guidance Note for Water Treatment in heating and

hot water systems the installer should check the hardness levels of the water supply

and if necessary ﬁ t an in-line scale inhibitor/reducer to provide protection to the

whole of the domestic water system.

1.0 DESIGN

Description

1.1 INTRODUCTION

If scale should ever become a problem the plate

heat exchanger is easily isolated and quickly

replaced with a service exchange unit which

can be obtained at a nominal cost from Gledhill.

For further details see Section 1 Hot and Cold

Water System page 10.

The pcb also incorporates the facility to operate

the heating pump for a few seconds every few

days when the heating is not being used, to

reduce the likelihood of the pumps sticking

as well as providing a boiler pump overrun

facility.

Any automatic boiler designed to operate on an

C ﬂ ow and a 71

C return up to a

maximum

of 35kW can be linked to any suitable model of

BoilerMate 2000 and the deciding factor is the

space heating and the hot water requirements

of a dwelling. See Section 1.2 Technical Data for

further details.

The BoilerMate 2000 is available with the

option of ‘Switch’ which will provide a 9kW

electrical emergency backup in case of failure

of the main heat source. See section 1.3 System

Remote

F&E tank

Full bore automatic bypass valve NOT REQUIRED

unless the heating system incorporates

mechanical thermostatic control valves e.g.

T.R.V's to all radiators or 2 port zone valves.

Primary flow

Primary

return

2000

Boiler

Warning/overflow

pipe

Cold feed

Mains cold

water

Open Vent

Page 5

BOILERMATE

2000

1.2 TECHNICAL DATA

Notes:-

1. The BoilerMate 225 appliance is suitable for use in large properties because it produces the same ‘peak hour output’ as a typical

350-400 litre unvented cylinder. [Ask for report - Unvented v’s Integrated Thermal Storage]. [Please note that this model requires

a larger cupboard and a 686mm wide door]. For properties requiring the BM 225 the incoming main should be a minimum of

35mm MDPE with a pressure of not less than 2 bar dynamic and an adequate ﬂ ow in line with the pipe sizing calculations.

In many cases, properties of this size will beneﬁ t from having 2 smaller sized appliances located adjacent to the areas of

peak hot water use. This will allow 2 heating zones to be provided and remove the need to provide a secondary circulation

on the hot water system.

2. Plastic feed and expansion cistern will be supplied separately including ballvalve, ﬂ oat and overﬂ ow ﬁ tting.

3. The ﬂ ow rates are based on a 35°C temperature rise and assume normal pressure and adequate ﬂ ow to the appliance. The actual

ﬂ ow rate from the appliance is automatically regulated to a maximum of 28 litres/min.

4. Models will be available in Hard and Soft water versions (sufﬁ xed ‘H’ or ‘S’).

5. Unit is supplied on a 100mm high installation base.

6. The domestic hot water outlet temperature is automatically regulated to approximately 55°C at the bath ﬂ ow rate of 18 litres/min

recommended by BS 6700. The temperature is not user adjustable.

1.0 DESIGN

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Page 6

1.2 TECHNICAL DATA

Standard Equipment

The standard conﬁ guration of the BoilerMate

2000 is shown opposite. The Appliance Control

Board (A.C.B.), mounted inside the appliance,

controls the operation of the complete system.

The A.C.B. is pre-wired to a terminal strip

where all electrical connections terminate. It

is supplied with the following factory ﬁ tted

equipment:-

1. Boiler pump

2. Domestic hot water primary

(plate heat exchanger) pump

3. Space heating pump

4. Hard water appliance control board

(A.C.B.)

5. Electro-mechanical clock to control the

space heating (in conjunction with room

thermostat - if ﬁ tted)

6. Plate heat exchanger

7. DHWS temperature sensor

8. PHE return sensor

9. Store temperature sensor

10. Y type strainer/ﬂ ow regulator

11. A feed and expansion cistern

complete with ballvalve, overﬂ ow

ﬁ tting and cold feed/open vent pipework

assembly is supplied separately.

Optional Equipment

* A soft water model is available for areas

where the hardness level is below 200

p.p.m. (mg/ltr)

* Flexible connectors for quick

connection to ﬁ rst ﬁ x pipe installation.

For further details see 2.2 Installation,

Pipework connections.

* ‘Switch’ emergency electrical back-up

for heating and hot water in the event

of a boiler fault.

* A seven day digital clock/programmer

to control the space heating (in

conjunction with a room thermostat if

ﬁ tted).

* A kit to site the clock/programmer

remotely.

* A no clock option - because of the

design of the appliance it should not be

necessary to fit anything other than a

single channel clock to control the

heating system.

* Hot and cold water manifolds for use with

plastic pipework.

1.0 DESIGN

Appliance Control Board

A.C.B.

Electro-mechanical clock

programmer

Digital clock programmer

‘Switch’

Page 7

BOILERMATE

2000

600mm min clear opening - if

located directly in front of the

appliance.

Maintenance

access

Min maintenance

access to comply with

the Water Regulations

CUPBOARD

300mm

420mm

280mm

600mm

100mm

*350mm

F & E Cistern

plan

1.0 DESIGN

1.2 TECHNICAL DATA

Note: The Appliance dimensions above do not allow for

the100mm high installation base

The following table of minimum cupboard dimensions only

allow the minimum space required for the appliance (including

the F & E cistern) and any extra space required for shelving etc

in the case of airing cupboards etc must be added.

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Note: The above dimensions are based on the Appliance and

the F & E cistern being in the same cupboard.

The BM 225 is wider than the other sizes and requires

a minimum 686mm wide door and a 750mm wide

cupboard.

Page 8

1.0 DESIGN

1.2 TECHNICAL DATA

Cut out area through

base of unit - showing

recommended pipework

riser positions.

120

408

595 (650)

595

555

REAR

PLAN

475

455

Safety/Open Vent Cold feed/Expansion

REMOVABLE FRONT ACCESS PANEL

325

405

450

(490)

365

(390)

295

(325)

230

(245)

195

(230)

130

(155)

(70)

TOP

Boiler Flow

Boiler Return

Heating Return

Primary Return

Summer use bathroom circuit

Heating Flow

Hot Supply

Cold Mains Supply

Suggested location for 15mm

cold mains feed to the F & E

tank.

The BoilerMate 2000 units are supplied on an installation base to allow the

pipe runs to connect to the appliance from any direction. It is easier if all

pipes protrude vertically in the cut out area shown. Compression or push

fit connections can be used and we do offer a set of flexible connectors as

an option. All pipe positions are approximate and subject to a tolerance of

+/- 20mm in any direction. A 15mm cold water supply and a 22mm

warning / overflow pipe will also be required for the separate feed and

expansion tank.

Dimensions in brackets apply to the 225 model only

Page 9

BOILERMATE

2000

1.2 TECHNICAL DATA

AWAITING HOT WATER PERFORMANCE GRAPHS FOR EACH MODEL SIZE

PERFORMANCE GRAPHS OF GRUNDFOS PUMPS

1.0 DESIGN

GRUNDFOS 15/50

litres/sec

GRUNDFOS 15/60

TO BE ADDED

Page 10

1.3 SYSTEM DETAILS

Hot and Cold Water System

General

A schematic layout of the hot and cold water services in a typical small dwelling is

shown below. BoilerMate 2000 will operate at mains pressures as low as 1 bar and as

high as 5 bar although the recommended range is 2-3 bar. If the manifolds (available as

an optional extra) are being used the inlet pressure to the manifold must be a minimum

of 2 bar. It is also important to check that all other equipment and components in

the hot and cold water system are capable of accepting the mains pressure available

to the property. If the mains pressure can rise above 5 bar or the maximum working

pressure of any item of equipment or component to be ﬁ tted in the system a pressure

limiting (reducing) valve set to 3 bar will be required.

If you encounter a situation where the water pressure is adequate but ﬂ ow rates are

poor please contact our technical helpline for details of an effective solution.

Note: Each BoilerMate 2000 is ﬁ tted with a strainer and ﬂ ow regulator on the cold

mains supply connection. If the supply pressure is less than 2 bar or if the manifolds

(available as an optional extra) are being used or if all taps are provided with ﬂ ow

regulators the ﬂ ow regulator on the cold inlet should be removed.

No check valve or similar device should be ﬁ tted on the cold water supply branch

to the BoilerMate 2000.

To comply with the Benchmark Guidance Note for Water Treatment in Heating and

Hot Water Systems the installer should check the hardness level of the water supply

and if necessary ﬁ t an in-line scale inhibitor/reducer to provide protection to the

whole of the domestic water system. See Appendix C for a copy of the relevant part

of the Benchmark Guidance Note.

1.0 DESIGN

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When specifying this appliance we would

recommend that for hardness levels above

200ppm (mg/l) a hard water appliance is used.

For hardness levels above 250ppm (mg/l) we

would recommend that some form of in-line

scale inhibitor/reducer is recommended by one

of the Water Treatment companies listed in the

Benchmark Guidance Note (see Appendix C).”

The hot water ﬂ ow rate from the BoilerMate

2000 is directly related to the adequacy of the

cold water supply to the dwelling. This must

be capable of providing for those services,

which could be required to be supplied

simultaneously, and this maximum demand

should be calculated using procedures deﬁ ned

in BS 6700.

If a water meter is ﬁ tted in the service pipe,

it should have a nominal rating to match the

maximum hot and cold water peak demands

calculated in accordance with BS 6700. This

could be up to 80ltr/min in some properties.

Page 11

BOILERMATE

2000

1.3 SYSTEM DETAILS

Hot and Cold Water System

Pipe Sizing / Materials

To achieve even distribution of the available supply of hot and cold water, it is

important in any mains pressure system, that the piping in a dwelling should be

sized in accordance with BS 6700. This is particularly important in a large property

with more than one bathroom.

However, the following rule of thumb guide lines should be adequate for most

smaller property types as long as water pressures are within the recommended

range of 2-3 bar.

1. A 15mm copper or equivalent external service may be sufficient for a

small 1bathroom dwelling (depending upon the flow rate available), but

the minimum recommended size for new dwellings is 22mm (25mm MDPE).

2. The internal cold feed from the main incoming stop tap to the BoilerMate

should be run in 22mm pipe. The cold main and hot draw-off should also

be run in 22mm as far as the branch to the bath tap.

3. The ﬁ nal branches to the hand basins and sinks should be in 10mm and to

the baths and showers in 15mm. (1 metre minimum)

4. We would recommend that best results for a balanced system are achieved

by ﬁ tting appropriate ﬂ ow regulators to each hot and cold outlet. This is

particularly relevant where the water pressures are above the recommended

water pressure range of 2-3 bar. Details of suitable ﬂ ow regulators are

provided in Appendix A.

Note: If manifolds (available as an optional extra) are being used suitable ﬂ ow

regulators are automatically provided in the manifold and do not need to be

provided at each outlet - See Appendix B for further details.

All the recommendations with regard to pipework systems in this manual are

generally based on the use of BS/EN Standard copper pipework and ﬁ ttings.

However, we are happy that plastic pipework systems can be used in place of copper

internally as long as the chosen system is recommended for use on domestic hot

and cold water systems by the manufacturer and is installed fully in accordance

with their recommendations.

This is particularly important in relation to use of push ﬁ t connections when using

the optional ﬂ exible hose kits - see 2.2 Installation, Pipework connections.

It is also essential that if an alternative pipework material/system is chosen the

manufacturer conﬁ rms that the design criteria of the new system is at least equivalent

to the use of BS/EN Standard copper pipework and ﬁ ttings.

Taps/Shower Fittings

Aerated taps are recommended to prevent splashing.

Any type of shower mixing valve can be used as long as both the hot and cold

supplies are mains fed. However, all mains pressure systems are subject to

dynamic changes particularly when other hot and cold taps/showers are opened

and closed, which will cause changes in the water temperature at mixed water

outlets such as showers. For this reason and because these are now no more

expensive than a manual shower we strongly recommend the use of thermostatic

showers with this appliance.

The shower head provided must also be suitable for mains pressure supplies.

However, if it is proposed to use a ‘whole body’ or similar shower with a number of

high ﬂ ow/pressure outlets please discuss with the Gledhill technical department.

1.0 DESIGN

The hot water supply to a shower-mixing valve

should be fed wherever practical directly from

the BoilerMate 2000 or be the ﬁ rst draw-off

point on the hot circuit. The cold supply

to a shower-mixing valve should wherever

practical be fed directly from the rising mains

via an independent branch. The shower must

incorporate or be fitted with the necessary

check valves to provide back-syphonage

protection in accordance with the Water

Regulations.

The supply of hot and cold mains water directly

to a bidet is permitted provided that it is of the

over-rim ﬂ ushing type and that a type ‘A’ air

gap is incorporated.

Hot and Cold Water System.

If the length of the hot water draw off pipework

is excessive and the delivery time will be more

than 60 seconds before hot water is available

at the tap, you may wish to consider using trace

heating to the hot water pipework such as the

Raychem HWAT system. Please consult Gledhill

Technical Department for further details.

It is important that the cold water pipework

is adequately separated/protected from any

heating/hot water pipework to ensure that

the water remains cold and of drinking water

quality.

Page 12

1.0 DESIGN

Heating System

General

A schematic layout of the heating system in a

typical small dwelling is shown opposite.

The flow and return from the boiler must

always run directly to the BoilerMate 2000

and the flow should rise continuously to

facilitate venting. The heating circuit is taken

from the BoilerMate 2000 and is piped in the

conventional manner.

The BoilerMate 2000 is only suitable for an

open vented system.

The F & E cistern can be ﬁ tted remotely up to

10m above the base of the BoilerMate 2000

i.e. the maximum static pressure in the store

must not exceed 1 bar.

If any radiators are located above the level

of the BoilerMate 2000 the system should

be designed so that gravity circulation does

not occur when the heating pump is not

running. To be certain of preventing this it is

recommended that a check valve, or valves, are

ﬁ tted on the vertical ﬂ ow pipes.

The water level in the F & E cistern should be

at least 250mm above the highest point on

the system including the radiators and must

be high enough to provide the minimum

head required by the boiler being used.

1.3 SYSTEM DETAILS

The boiler manufacturer’s instructions with

regard to minimum head must always be

followed. This is particularly important in

situations where the headroom is restricted

(e.g. in a ﬂ at).

Range rated boilers can be used but should

always be set at the highest output. The

system efﬁ ciency will not be impaired while

the recovery rate will be improved.

It is not necessary to provide a boiler bypass

on the primary circuit with thermal storage

appliances (i.e. between the boiler and the

thermal store.)

Remote

F&E tank

Full bore automatic bypass valve NOT REQUIRED

unless the heating system incorporates

mechanical thermostatic control valves e.g.

T.R.V's to all radiators or 2 port zone valves.

Primary flow

Primary

return

2000

Boiler

Warning/overflow

pipe

Cold feed

Mains cold

water

Open Vent

Page 13

BOILERMATE

2000

1.0 DESIGN

1.3 SYSTEM DETAILS

Pipe Sizing/Materials

The primary pipework connecting the boiler and the thermal store should be sized

to achieve a maximum of 8°C rise across the boiler or the maximum temperature

rise speciﬁ ed by the boiler manufacturer, whichever is smaller, but in any instance it

should not be less than 22mm copper tube.

Note: There should be no valves in the pipework connecting the boiler to the

BoilerMate 2000.

The heating circuit operates on the normal primary boiler temperatures i.e. 82°C

ﬂ ow and 71°C return. Therefore any traditional hot water radiators or convectors

can be used with this system and no special over-sizing of the heat emitters is

necessary.

All the recommendations with regard to pipework systems in this manual are

generally based on the use of BS/EN Standard copper pipework and ﬁ ttings.

However, we are happy that plastic pipework systems can be used in place of

copper internally as long as the chosen system is recommended for use on domestic

heating systems by the manufacturer and is installed fully in accordance with

their recommendations. We always recommend the use of barrier pipe for these

systems.

Heating System

F & E Cistern

Primary flow

Primary return

BM 2000

Boiler

It is also essential that if an alternative pipework

material/system is chosen the manufacturer

confirms that the design criteria of the new

system is at least equivalent to the use of BS/EN

Standard copper pipework and ﬁ ttings.

Boiler Size

It is only necessary to calculate the heating

requirements in accordance with BS 5449. The

allowances shown below should be added

for domestic hot water. The control system

automatically gives priority to hot water when

necessary.

Boiler Sited Below BoilerMate 2000

Any boiler can be used when the flow pipe

from the boiler to the BoilerMate 2000 rises

continuously. No valve shall be ﬁ tted in the

primary ﬂ ow or open vent.

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Page 14

1.0 DESIGN

1.3 SYSTEM DETAILS

Any boiler used must be ﬁ tted with an overheat

thermostat i.e. it must be suitable for use in

a sealed system.

The F & E cistern must be ﬁ tted at a height

which will provide the minimum head required

for the boiler and must be at least 250mm

above the highest point of the system.

The height of the water level in the F & E cistern

from the base of the store should be no greater

than 10m.

A gravity check valve should be ﬁ tted in the

boiler return pipework to prevent gravity

circulation between the BoilerMate 2000 and

the boiler during dormant periods.

An automatic air vent will be required on the

flow adjacent to the boiler and depending

upon the pipe layout a manual air vent may

also be required on the return adjacent to

the boiler.

Boiler sited with dipped flow and return

pipes to the BoilerMate

Any boiler must be fitted with an overheat

thermostat i.e. it must be approved for use in

a sealed system.

An automatic air vent will be required on the

ﬂ ow and return connections adjacent to the

boiler.

The height of the water level in the F & E cistern

must provide the minimum head required by

the boiler and must be at least 250mm higher

than the highest point of the system.

Boiler sited above the BoilerMate

Heating System

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0RIMARYRETURN

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#6

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#6'RAVITYCHECKVALVE

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0RIMARYFLOW

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Page 15

BOILERMATE

2000

1.0 DESIGN

1.3 SYSTEM DETAILS

Connection of Bathroom Radiator/

Towel-Rail for Summer use

If a pumped circuit is required for the bathroom

radiator/towel rail, the ﬂ ow pipework can be

teed anywhere into the primary ﬂ ow between

the boiler and the BoilerMate. The return

pipework can be connected into the 15mm

copper blanked connection provided adjacent

to the boiler pump. We recommend any

radiators/towel rails on this circuit are provided

with T.R.V.’s and that the total heat output of

the radiators/towel rails is not more than 5%

of the boiler output.

The radiators will only get hot when the

boiler is ﬁ ring.

It is important that the ﬂ ow rates through these

radiators is adjusted to the minimum required

at the lockshield valves on the radiators. If this

is not done the performance of the BoilerMate

will be adversely affected.

If heating of a single bathroom radiator or

towel rail is required in summer, then it can

be piped as a gravity circuit. The ﬂ ow pipe to

the radiator can be teed into the safety open

vent pipe and the return pipe from the radiator

can be connected to the store drain connection

and the drain moved to the return pipe. The

radiator can be ﬁ tted with a T.R.V. if required as

long as this is suitable for gravity circulation i.e.

low resistance type.

Heating System

The height of the water level in the F & E cistern

must provide the minimum head required by

the boiler and must be at least 250mm higher

than the highest point of the system.

The height of the water level in the F & E cistern

must provide the minimum head required by

the boiler and must be at least 250mm higher

than the highest point of the system.

F & E Cistern

BM 2000

Boiler

Radiator

F & E Cistern

BM 2000

D.V.

D.V. : Drain valve

Page 16

1.3 SYSTEM DETAILS

Heating System

Method of connecting two BoilerMates to one heat source.

If the primary ﬂ ow and return pipework continuously rises from the boiler to the

BoilerMate the recommended method for connecting two BoilerMates to one heat

source is to ﬁ t the BoilerMates as normal but to provide a single check valve on the

branch immediately after each primary pump.

The heating and hot water from each appliance must serve separate zones/bathrooms

within the property.

The electrical supplies from each appliance to the boiler will need twinning so that

the boiler will operate on a call from either/both appliances.

Both primary pumps and the primary pipework sizes should be checked to ensure

that they are adequate for the system that has been installed.

If the primary pipework dips or the boiler is located above the BoilerMate

a single F & E cistern with a cold feed and open vent piped to the cistern

should be used.

This arrangement is not suitable for BoilerMate appliances ﬁ tted with Switch.

If it is proposed to use this arrangement please advise Gledhill at the time of order,

Gledhill will then supply a suitable vent assembly for ﬁ tting on the safety/open vent

connection and a blank for the cold feed connection of each BoilerMate 2000, in

lieu of the F & E cistern normally provided.

If the boiler is a long way from the BoilerMate the resistance should be checked

to ensure the pumps cannot produce a negative pressure in the BoilerMate

appliance.

The single F & E cistern will need to be provided, (by the installer) and be suitable

for the size of the total system installed.

For further details please ring the Gledhill Technical helpline.

1.0 DESIGN

Page 17

BOILERMATE

2000

1.3 SYSTEM DETAILS

‘Switch’

The BoilerMate 2000 can be ordered with

the option of ‘Switch’ which provides a 9kW

electrical emergency back up in the case of

failure of the main heat source i.e. gas boiler.

This must NOT be used to provide hot

water only in summer if the main system is

working correctly.

If Switch is ordered the electrical supply will

need to take account of the increased load.

Full details of the requirements are provided

in Section 2.1 Site Requirements and 2.2

Installation.

Otherwise the design requirements are the

same as the standard appliance.

Switch can operate on ‘hot water’ or ‘hot water

and heating’ modes. In the former only hot

water pump and electric heating element are

energized. In the latter the heating system

pump is also energized. This means that

the heating will be on permanently unless

manually switched back to the ‘hot water’ only

position.

It also means that wherever Switch is

being used the normal domestic hot water

temperature controls are over-ridden. Initially

dependent on the ﬂ ow rate/store temperature

hot water can be delivered at the tap at

temperatures as high as 75°C. A warning

notice to this effect is provided in the front

of the appliance.

However, once the initial store temperature has

been reduced the Switch element thermostat

will reduce the temperature at the tap to no

more than 65°C. Full details of how to operate

the system are provided on a label ﬁ xed to the

front of the appliance.

1.0 DESIGN

Page 18

Electrical Supply requirements for BoilerMate

2000

with Switch

2.0 INSTALLATION

2.1 SITE REQUIREMENTS

The appliance is designed to be installed in an airing/cylinder cupboard and the

relevant minimum dimensions are provided in section 1.2 Technical Data.

Because of the ease of installation we recommend that the cupboard construction

is completed and painted before installation of the appliance. The cupboard door

can be ﬁ tted after installation.

If the unit needs to be stored prior to installation it should be stored upright in a

dry environment and on a level base/ﬂ oor.

Installation and maintenance access is needed to the front of the appliance and

above the F & E cistern. See Technical Data section for further details.

The minimum dimensions contained in section 1.2 Technical Data allow for the

passage/connection of pipes to the appliance from any direction as long as the

appliance is installed on the installation base provided. If the installation base is

not used extra space may be needed to allow connection to the pipework and the

whole of the base area should be continuously supported on a material which will

not easily deteriorate if exposed to moisture.

The ﬂ oor of the cupboard needs to be level and even and capable of supporting

the weight of the appliance when full. Details of the weight when full is provided

in section 1.2 Technical Data.

The appliance is designed to operate as quietly as practicable. However, some noise

(from pumps etc) is inevitable in any heating system. This will be most noticeable

in cupboards formed on bulkheads, or at the mid span of a suspended ﬂ oor. In these

cases the situation can be improved by placing the appliance on a suitable sound

deadening material (i.e. carpet underlay or similar).

Cupboard temperatures will normally be higher than in a conventional system

and the design of the cupboard and door will need to take this into account. No

ventilation is normally required to the cupboard.

A suitable location will be needed for the separate feed and expansion cistern.

This will often be at high level in the cupboard housing the BoilerMate 2000. The

dimensions and clearances are provided in section 1.2 Technical Data. The location

will need to provide a suitable route for the cold feed and expansion pipe as well

as the open safety vent pipe. The location will also need to provide a suitable

route and discharge position for the warning/overﬂ ow pipe and the ballvalve supply

from the mains cold water system.

An electrical supply must be available which is

correctly earthed, polarized and in accordance

with the latest edition of the IEE requirements

for electrical Installations BS 7671.

The electrical mains supply needs to be

230V/50Hz.

Connection must be made using a double-pole

linked isolator with a contact separation of

3mm in both poles which is located within 1m

of the appliance. The supply must only serve

the appliance.

The supply to the standard appliance shall be

fused at 3 amp.

If the ‘Switch’ electrical emergency backup

is being provided, the minimum breaking

capacity of the main isolation switch and

cable sizes/lengths at 230V shall follow the

recommendations in the table below.

Nominal

full load

current

Min rating of

isolating

switch

Cable size

Max. recommended

cable run-based on

9.2V drop and 0.4

second disconnection

time using a type

1 or B breaker

41.0 Amps 45 Amps 10 mm

49 metres

Recommended circuit

protection device - based on

0.4 second disconnection

time

45 A type 1 - MCB to BS 3871

45A type B circuit breaker to BS EN

60898

Page 19

BOILERMATE

2000

2.2 INSTALLATION

2.0 INSTALLATION

HANDLING

When lifting the unit work with someone of similar build

and height if possible.

Choose one person to call the signals.

Lift from the hips at the same time, then raise the unit to

the desired level.

Move smoothly in unison.

Preparation/placing the appliance in

position.

Details of the recommended positions for

termination of the first fix pipework are

provided in section 1.2 Technical Data. The

pipework can be located or its position

checked using the template provided with

each appliance. If these have been followed

installation is very simple and much quicker

than any other system.

The appliance is supplied shrink wrapped on a

timber installation base. Carrying handles are

also provided in the back of the casing.

The feed and expansion cistern complete with

ballvalve, cold feed/expansion and overﬂ ow/

warning fittings are provided in a separate

box. If ﬂ exible connections have been ordered

these will also be inside the feed and expansion

cistern.

The appliance should be handled carefully to

avoid damage and the recommended method

is shown opposite. Before installation the

site requirements should be checked and

conﬁ rmed as acceptable. The plastic cover and

protective wrapping should be removed from

the appliance the installation base (provided)

placed in position.

The appliance can then be lifted into position

in the cupboard on top of the base and the

front panel removed by unscrewing the 2

screws and lifting the door up and out, ready

for connection of the pipework and electrical

supplies. The feed and expansion cistern

support shall be installed ensuring that the

base is fully supported and the working

head of the appliance is not exceeded and

the recommended access is provided for

maintenance - see section 1.2 Technical Data.

Note: Although the above guidance is provided

any manual handling/lifting operations will

need to comply with the requirements of

the Manual Handling Operations Regulations

issued by the H.S.E.

The appliance can be moved using a sack truck

on the rear face although care should be taken

and the route should be even.

In apartment buildings containing a number

of storeys we would recommend that the

appliances are moved vertically in a mechanical

lift.

If it is proposed to use a crane expert advice

should be obtained regarding the need for

slings, lifting beams etc.

A speciﬁ c manual handling assessment is shown in Appendix D

at the rear of this manual.

Page 20

The position of the pipework connections is

shown opposite. The connection sizes and

dimensions are listed in Section 1.2 Technical

Data.

All the connections are also labelled on the

appliance. It is essential that the pipework is

connected to the correct connection.

The connections can be hard piped but we

recommend the use of ﬂ exible connections

(available as an optional extra).

If using push ﬁ t connectors with the ﬂ exible

hose kits it is important to check that they

are compatible. Written approval has already

been obtained for:-

Hepworth - Hep

O BiTite

John Guest - Speedﬁ t

Yorkshire - Tectite

However, as similar assurances cannot be

obtained for Polypipe fittings we cannot

recommend their use.

Connections A, B, C, F and H are plain ended

copper pipe.

Connections D, G and I are compression

ﬁ ttings.

Connection E is blanked 15mm copper pipe

Connection J is RC½ (½ in BSPT internal).

A - Safety open vent

B - Cold feed/expansion

C - Primary ﬂ ow (from boiler)

D - Primary return (to boiler)

E - Towel rail circuit return

F - Central heating return

G - Central heating ﬂ ow

H - Domestic hot water

I - Incoming mains cold water

J - Drain (valve is not provided with the

appliance)

2.0 INSTALLATION

2.2 INSTALLATION

Pipework connections

Note: The safety open vent and cold feed/

expansion should be connected to the

F & E cistern using the pipework assembly

provided.

All factory made joints should be checked

after installation in case they have been

loosened during transit.

The ﬁ ttings for the feed and expansion cistern

should be installed following the instructions

provided by the manufacturer in a position

to suit the particular location and the cistern

ﬁ tted on its supports/base.

The cold feed/expansion and safety open vent

should be installed between the appliance and

the feed and expansion cistern.

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Gledhill BoilerMate 2000 Owner's manual

Brand: Gledhill

Model: BoilerMate 2000

Category: Water heaters & boilers

Type: Owner's manual

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Gledhill BoilerMate 2000 Owner's manual

Gledhill BoilerMate 2000 Owner's manual

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